Independent doffer drive system for a cotton harvester row unit

ABSTRACT

A doffer assembly for a cotton harvester having at least one drum and a spindle. The doffer assembly includes an outer housing and a plurality of doffers adapted to remove cotton from the spindle. The assembly further includes a drive unit coupled to the outer housing for rotatably driving the plurality of doffers independently of at least one drum and spindle. A drive shaft is rotatably driven by the drive unit, and an interface adapter is coupled between the drive shaft and the plurality of doffers. The drive unit may be an electric motor, hydraulic motor, a mechanical drive system, or a combination thereof.

FIELD OF THE DISCLOSURE

The present disclosure relates to a doffer drive system, and inparticular to an independently controlled doffer drive system of acotton harvester row unit.

BACKGROUND OF THE DISCLOSURE

Cotton harvester units include a number of spindles and doffers forharvesting cotton. Doffer columns have a plurality of doffers forremoving picked cotton from the spindles. A doffer is a disc that may becoated in rubber or urethane and rotatably driven at a velocity muchgreater than that of the spindles. In a conventional cotton harvesterrow unit, the spindles move underneath the bottom face of the doffers sothat the cotton is unwrapped and stripped from the spindles. In thisconventional system, a doffer drive system is mechanically driven off aspindle drive system, or at the very least the two systems aremechanically coupled to one another. Mechanical coupling of the dofferand spindle drive systems enables the speed relationships to bemaintained, and also achieves proper functionality when the systemsoperate in harvest mode. In other words, the spindles can operate in adesirable direction of travel.

There are, however, circumstances or applications in which independentcontrol of the doffer may be desirable and which conventional systemsare unable to achieve. In particular, it may be desirable to haveindependent control when a row unit plug is being cleared. When a rowunit plugs, spindles often become wrapped with cotton which can jam orinterfere with the desirable forward rotation of the picking unitcomponents. Thus, a need exists to independently control the dofferdrive system and spindle doffer system from one another so that when thespindles become plugged, the doffers can continuously be driven in theforward direction while the spindles are rotatably driven in a reversedirection. In doing so, the doffers could unwrap the cotton from thespindles without requiring any manual intervention.

SUMMARY

In one embodiment of the present disclosure, a doffer assembly for acotton harvester having at least one drum and a spindle, including anouter housing; a plurality of doffers adapted to remove cotton from thespindle of the harvester; a drive unit coupled to the outer housing forrotatably driving the plurality of doffers independently of at least onedrum and spindle; a drive shaft rotatably driven by the drive unit; andan interface adapter coupled between the drive shaft and the pluralityof doffers.

In a first example of this embodiment, the doffer assembly may include adrive coupler coupled to the drive shaft; and a driven coupler coupledto the drive coupler and the interface adapter. In a second example, thedrive unit includes an electric or hydraulic motor. In a third example,the drive unit is axially aligned with the plurality of doffers. In afourth example, the doffer assembly may include a doffer adjustmentdevice for axially adjusting the plurality of doffers relative to thedoffer housing, the doffer adjustment device including a dofferadjustment shaft and a doffer adjustment ring gear.

In another embodiment of the present disclosure, a picker unit assemblyof a cotton harvester, includes a drum and a plurality of spindlesrotatably coupled to the drum; a drum and spindle drive unit forrotatably driving the drum and the plurality of spindles; a dofferassembly including a plurality of doffers configured to remove cottonfrom the plurality of spindles; and a doffer drive unit for rotatablydriving the doffer assembly, wherein the doffer drive unit rotatablydrives the doffer assembly independently of the plurality of spindles.

In one example of this embodiment, the doffer drive unit includes anelectric motor. In a second example, the picker unit may include aninverter for providing electrical power to the motor for driving thedoffer assembly, the inverter further adapted to detect a conditionrelated to doffer wear or a plug based on feedback received from themotor. In a third example, the picker unit may include a second dofferassembly including a plurality of doffers configured to remove cottonfrom a second plurality of spindles, wherein the second doffer assemblyis rotatably driven independently of the first and second plurality ofspindles. In a fourth example, the doffer drive unit rotatably drivesboth the first and the second doffer drive assemblies.

In a further example, the picking unit may include a second doffer driveunit for rotatably driving the second doffer assembly; and an inverterfor electrically powering the first and second doffer drive units. Inyet a further example, the doffer drive unit comprises a hydraulic motorfor hydraulically powering the plurality of doffers. In yet anotherexample, the picking unit may include a second doffer assembly includinga plurality of doffers configured to remove cotton from a secondplurality of spindles, wherein the second doffer assembly is rotatablydriven independently of the first and second plurality of spindles; anda second doffer drive unit for hydraulically powering the second dofferassembly.

In a further embodiment of the present disclosure, a cotton harvesterincludes a drive unit for producing mechanical power; a controller forcontrolling the cotton harvester; a plurality of picker units configuredto harvest cotton, wherein each of the plurality of picker unitsincludes a drum; a plurality of spindles rotatably coupled to the drum;a drum and spindle drive for rotatably driving the drum and theplurality of spindles; a doffer assembly including a plurality ofdoffers configured to remove cotton from the plurality of spindles; anda doffer drive unit for rotatably driving the doffer assembly, whereinthe doffer drive unit rotatably drives the doffer assembly independentlyof the drum and spindle drive.

In one example of this embodiment, the doffer drive unit includes anelectric motor or hydraulic motor. In a second example, the plurality ofpicking units includes a first picking unit and a second picking unit,the first picking unit and the second picking unit each including adoffer drive unit and a doffer assembly, the doffer drive unit includinga front doffer drive unit and a rear doffer drive unit, and the dofferassembly including a front doffer assembly and a rear doffer assembly;further wherein, the front doffer drive unit of the first and secondpicking units operably drives the respective front doffer assembly, andthe rear doffer drive unit of the first and second picking unitsoperably drives the respective rear doffer assembly.

In a third example, the cotton harvester may include a first inverterfor electrically controlling the front doffer drive unit and rear dofferdrive unit of the first picking unit; and a second inverter forelectrically controlling the front doffer drive unit and rear dofferdrive unit of the second picking unit; wherein, the first inverter andsecond inverter are in electrical communication with the controller. Ina fourth example, the cotton harvester may include a hydraulic pumpoperably driven by the drive unit; a first hydraulic valve fluidlycoupled to the hydraulic pump, the first hydraulic valve hydraulicallycontrolling the front doffer drive unit and rear doffer drive unit ofthe first picking unit; and a second hydraulic valve fluidly coupled tothe hydraulic pump, the second hydraulic valve hydraulically controllingthe front doffer drive unit and rear doffer drive unit of the secondpicking unit.

In another example, the plurality of picking units includes a firstpicking unit and a second picking unit; the doffer assembly of the firstpicking unit includes a first front doffer assembly and a first reardoffer assembly; the doffer assembly of the second picking unit includesa second front doffer assembly and a second rear doffer assembly; thedoffer drive unit of the first picking unit operably drives the firstfront doffer assembly and the first rear doffer assembly; and the dofferdrive unit of the second picking unit operably drives the second frontdoffer assembly and the second rear doffer assembly.

In a further example of this embodiment, the cotton harvester mayinclude a hydraulic pump operably driven by the drive unit; a firstpicking unit of the plurality of picking units, the first picking unitincluding a first front doffer assembly and a first rear dofferassembly, where the doffer drive unit operably drives the first reardoffer assembly; a second picking unit of the plurality of pickingunits, the second picking unit including a second front doffer assemblyand a second rear doffer assembly; and a hydraulic valve fluidly coupledto the hydraulic pump, the hydraulic valve hydraulically controlling thefirst doffer drive unit; wherein, the first front doffer assembly andthe first rear doffer assembly are mechanically coupled to one another,and the second front doffer assembly and the second rear doffer assemblyare mechanically coupled to one another; wherein, the first rear dofferassembly and the second rear doffer assembly are mechanically coupled toone another; further wherein, the second front doffer assembly and thesecond rear doffer assembly are rotatably driven by the doffer driveunit via the mechanical coupling between the first rear doffer assemblyand the second rear doffer assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned aspects of the present disclosure and the manner ofobtaining them will become more apparent and the disclosure itself willbe better understood by reference to the following description of theembodiments of the disclosure, taken in conjunction with theaccompanying drawings, wherein:

FIG. 1 is a perspective view of a portion of a conventional cottonharvester unit;

FIG. 2 is a side cross-sectional view of an independent doffer drivesystem;

FIG. 3 is a control schematic of a first embodiment of an independentdrive system;

FIG. 4 is a control schematic of a second embodiment of an independentdrive system;

FIG. 5 is a control schematic of a third embodiment of an independentdrive system;

FIG. 6 is a control schematic of a fourth embodiment of an independentdrive system; and

FIG. 7 is a control schematic of a fifth embodiment of an independentdrive system.

Corresponding reference numerals are used to indicate correspondingparts throughout the several views.

DETAILED DESCRIPTION

The embodiments of the present disclosure described below are notintended to be exhaustive or to limit the disclosure to the preciseforms in the following detailed description. Rather, the embodiments arechosen and described so that others skilled in the art may appreciateand understand the principles and practices of the present disclosure.

Referring to FIG. 1, a conventional cotton harvester unit 100 isillustrated. The illustrated cotton harvester unit 100 may include aplurality of picking units. In FIG. 3, for example, the cotton harvesterunit may include up to six different picking units. Other machines mayinclude a different number of picking units. In any event, each unit mayinclude a frame 115. A drum 120 is rotatably coupled to the frame 115.In at least one picking unit, there may be a front drum 120 and a reardrum 120. A plurality of rows of spindles 125 is rotatably coupled toeach drum 120. A doffer column 130 having a plurality of doffers 135 isrotatably supported by a bearing housing (not shown). The plurality ofdoffers 135 is positioned adjacent the spindles 125 and configured toremove cotton from the spindles 125. The bearing housing (not shown) maybe threadably engaged with a fixed housing (not shown), which is coupledto the frame 115.

In the conventional system of FIG. 1, power comes into a gearbox andtransfers via an output shaft to an idler gear stack (not shown). Thepower is split between the drum and spindles. A gear connects thedoffers to the spindles such that a relationship between the speeds ofthe doffers and spindles is maintained. In this system, the doffers andspindles are rotationally driven by the same drive system.

Referring to FIG. 2, one embodiment of an independent doffer drivesystem 200 is illustrated. In this embodiment, the system includes anouter doffer housing 202 and a top cover 220 that define an inner cavityin which a doffer adjustment device including a shaft 204 is disclosed.The top cover 220 may be coupled to the doffer housing 202 via one ormore fasteners 222. For purposes of this disclosure, the dofferadjustment device may be similar to that disclosed in in U.S. Pat. No.8,572,941 to Deere & Company.

A doffer retention bolt 206 may extend vertically through the dofferadjustment shaft 204 an inner cavity of the doffer housing 202. Thedoffer adjustment device may further include a doffer adjustment ringgear 208. The ring gear 208 may be removably coupled to a bearinghousing 212 via one or more fasteners 210. The bearing housing 212 maydefine a location to substantially enclose a bearing 214, such as aroller bearing, which provides support to the adjustment shaft 204. Alocknut or fastener 232 may also substantially surround the dofferadjustment shaft 204 as shown in FIG. 2.

As also shown, the system 200 may include a drive unit 216. In thisembodiment, the drive unit 216 is shown as an electric motor. Theelectric motor may include a motor shaft 218 for providing input powerto the doffer unit. In this embodiment, the drive unit 216 and shaft 218are axially aligned with the doffer housing 202 and plurality of doffers(not shown). In this manner, the motor shaft 218 is disposed along avertical axis defined therethrough, and a doffer column may be arrangedaxially along the vertical axis. Power from the motor may be transferredfrom the shaft 218 to a motor coupler 224. The motor coupler 224 mayinclude internal splines that are coupled to corresponding splines onthe motor shaft 218. Likewise, the motor coupler 224 may includeexternal splines or a tapered shaft with a key that are coupled to acomplimentary coupler 230. The driven coupler 230 may be further coupledto a coupler interface adapter 226 via one or more fasteners 228 such asbolts, screws, and the like. The coupler interface adapter 226, orsecond coupler, may replace a conventional doffer driven gear that ispresent in the embodiment of FIG. 1. Conventionally, the doffer drivengear receives mechanical power from the gear stack to drive the dofferunit. In the embodiment of FIG. 2, however, electrical power from theelectric motor 216 drives the doffer unit independently from the drumand spindle drive.

While an electric motor is depicted in FIG. 2 as the drive unit, forpurposes of this disclosure any known type of drive unit may be used todrive the doffer unit. For instance, the doffer system may be drivenelectrically, hydraulically, or mechanically. Examples of thesedifferent embodiments are shown in FIGS. 3-7.

One of the advantages of an electric motor is its ability to provideintegrated speed and load sensing outputs. As will be described, thismay be implemented by a single motor on each doffer, or a single motorfor driving a front and a rear doffer in a single row unit. Thisindependent drive, through integrated doffer load sensing, may providefeedback for a self-adjusting doffer. It may also provide feedback fordoffer plug detection and automatic plug clearing. In conventional rowunit systems, such as the one show in FIG. 1, the drum, spindles, anddoffers may be rotatably driven in a reverse direction to assist withunplugging cotton from the spindles. This, however, sometimes wouldfurther wind the cotton around the spindles, and a machine operator mayhave to manually assist with unplugging the cotton from the spindles. Byindependently driving the doffer system, the doffers may continue torotate in the forward direction while the drum and spindles may berotatably driven in the reverse direction to clear the plugged cottonfrom the row unit.

In addition to clearing the plugged cotton, the independent doffer drivesystem may further detect the plugged condition. With an electric motorand inverter system, such as the one illustrated in FIGS. 3 and 4, thesystem may detect current draw of the motor. Besides current, motorspeed and direction of rotation may also be monitored. An inverter maycontrol the motor via current draw and detect the type or amount of loadon the motor. When cotton plugs, the inverter may detect an increase incurrent needed to drive the motor or a decrease in motor speed. Theinverter may take the form of an inverter controller and function bothas a controller for controlling the motor operation and invertingcurrent into a three-phase. By controlling the motor, the inverter mayreceive inputs from the motor and compare the inputs to threshold valuesto determine a plugged condition. As will be described below, theinverter may be electrically coupled to a Controller Area Network (CANbus) for communicating with other controllers. In this manner, othercontrollers may detect the plugged condition based on informationcommunicated over the CAN by the inverter.

The inverter and electric motor system may also provide the benefit of adoffer health indicator. As is known, the plurality of spindles of a rowunit are rotationally driven and pass beneath the doffers of the doffersystem. In doing so, the doffers contact and remove the cotton from thespindles. However, over a period of time, the doffers may begin to wear.In particular, a leading edge or corner of the doffer may begin to wearsuch that it may round off or develop a radius. As the doffer leadingedge begins to round off, its doffing efficiency can decrease. With adecreased doffing efficiency, the doffer may be prone to wrap the cottonaround the spindles rather than remove it. If not properly maintained, aload can be imposed on the doffer drive system for driving the doffer.

With the load sensing capability of the electric motor and inverter, aworn doffer may be detected by comparing the loads on the motor to athreshold load. If the detected load exceeds the load threshold, thenthe inverter controller or another system controller may detect a worndoffer. The worn doffer may be replaced or appropriate maintenance maybe carried out. As for the load, the motor torque may gradually increaseover time as the doffer wears. By contrast, if cotton plugs the system,the motor torque may increase instantly or much quicker than when dofferwear is detected. In any event, the health of the doffer system may bedetectable by the independent doffer drive system.

For purposes of this disclosure, an electric drive system is only one ofseveral embodiments contemplated herein. An independently controlledhydraulic doffer drive system is also possible. In this embodiment,hydraulic pressure may be measured to detect a plugged condition ordoffer wear, and the pressure may be compared to a pressure threshold.With a hydraulic system, load and speed sensing may be executed bypressure and speed sensors, respectively.

Moreover, an independent mechanical doffer drive system is alsopossible. Here, power shafts may transfer power from a centralized ormain drive system. A gear case may then transfer the mechanical power tothe row units. Other means may be possible including gears, for example.

Referring now to FIG. 3, a first embodiment of a control system 300 forcontrolling an independent doffer drive system of a cotton harvesterunit is shown. The harvester unit may include a main drive unit such asan engine 302. The engine 302 may produce mechanical power that drives agearbox or auxiliary drive unit 304. The mechanical power from theengine 302 may be converted to electrical power via a generator unit306. Various electronics 308 may allow for voltage control to control aplurality of different picking units, which will be described below.

The control system 300 may include a main controller 310 such as a headinterface controller (HIC). The main controller 310 may be in electricalcommunication with the generator unit 306 and electronics 308 via acommunication network such as a CAN bus 312. The main controller 310 maycommunicate to or receive voltage commands from the electronics 308. Inany event, electrical power may be supplied to the plurality of pickingunits as shown in FIG. 3.

In this embodiment, the cotton harvester unit may include four pickingunits, namely, a first picking unit 314, a second picking unit 316, athird picking unit 318, and a fourth picking unit 320. In anotherembodiment, however, there may be six picking units. In a furtherembodiment, there may be two picking units. The present disclosure isnot limited to any number of picking units, and thus the independentdoffer drive may be incorporated into any number of picking units basedon the teachings of the present disclosure.

Each picking unit may include a spindle and drum drive and a front andrear doffer drive assembly. In one such example, the picking unit mayinclude a front drum and a rear drum. In this example, a plurality ofspindles may be rotatably driven by the front drum and a plurality ofspindles may be rotatably driven by the rear drum. In any event, thefront doffer drive assembly and rear doffer drive assembly may beindependent from the drum and spindle drive. In FIG. 3, for example, thefirst picking unit 314 may include a drum and spindle drive 322, a frontdoffer assembly 324, a front doffer drive unit 356, a rear doffer driveunit 358, and a rear doffer assembly 326. For purposes of orientation,“front” is intended to refer to a front end of the picking unit, and“rear” is intended to refer to a rear end of the picking unit. Moreover,for purposes of this disclosure, “doffer drive assembly” may include thedoffer assembly similar to that illustrated in FIG. 2 and a drive unitsuch as an electric or hydraulic motor. The doffer assembly may includea plurality of doffers arranged in a column similar to that in FIG. 1,where the plurality of doffers are arranged adjacent to a plurality ofspindles for doffing cotton therefrom. As will be described below, thedoffer assembly may be independently driven by the doffer drive unit,which in FIGS. 3-4 is shown as electric motors and in FIGS. 5-7 ashydraulic motors.

The second picking unit 316 may include a drum and spindle drive 328, afront doffer assembly 330, and a rear doffer assembly 332. Likewise, thethird picking unit 318 may include a drum and spindle drive 334, a frontdoffer assembly 336, and a rear doffer assembly 338. Further, the fourthpicking unit 320 may include a fourth drum and spindle drive 340, afront doffer assembly 342, and a rear doffer assembly 344.

As in a conventional harvester unit, each drum and spindle drive may bemechanically driven by a mechanical power unit 346. For instance, theengine 302 may provide mechanical power to a gear case which providespower to the drum and spindle drives. In FIG. 3, mechanical power 346may be provided to the second drum and spindle drive 328, which ismechanically coupled to the first drum and spindle drive 322. As such,mechanical power 346 is transferred through a first flow path to thefirst and second drum and spindle drives of the first and second pickingunits, respectively. Likewise, mechanical power 346 may be transferredthrough a second flow path to the third and fourth drum and spindledrives of the third and fourth picking units, respectively. Thus, thereis a mechanical coupling between the first and second picking units andthe third and fourth picking units.

The independent doffer drive system of FIG. 3 includes acontroller/inverter for each picking unit. For example, the firstpicking unit 314 includes a first controller/inverter 348. Similarly,the second picking 316 includes a second controller/inverter 350, thethird picking unit 318 includes a third controller/inverter 352, and thefourth picking unit 320 includes a fourth controller/inverter 354. Eachcontroller/inverter may function in a manner similar to that previouslydescribed. Moreover, each controller/inverter may include dual outputs,or it may be a dual controller/inverter each with individual outputs.

In the embodiment of FIG. 3, the front and rear doffer assemblies may beelectrically driven by its own electric motor. For example, in the firstpicking unit 314, the front doffer assembly 324 may be electricallypowered by a first front motor 356 and the rear doffer assembly 326 maybe electrically powered by a first rear motor 358. The first front motor356 and first rear motor 358 may be in electrical communication with thefirst controller/inverter 348. In one aspect, wires or cables mayelectrically couple each motor to the first controller/inverter 348. Ina different aspect, the controller/inverter may wirelessly communicatewith each motor.

Similar to the first picking unit, the second front doffer assembly 330may be electrically powered by a second front motor 360. The second reardoffer assembly 332 may be electrically powered by a second rear motor362. The front motor 360 and rear motor 362 may each be electricallycoupled or at least in electrical communication with the secondcontroller/inverter 350. Electrical wires or cables may electricallycouple the second controller/inverter 350 to each of the second motors,or communication may be via wireless communication.

In the third picking unit 318, the third front doffer assembly 336 maybe electrically driven by a third front motor 364, and the third reardoffer assembly 338 may be electrically driven by a third rear motor366. In each case, the doffer assemblies are electrically drivenindependently of the drum and spindle drive. The front and rear electricmotors of the third picking unit 318 may be electrically coupled or atleast in electrical communication with the third controller/inverter352. Electrical communication may be via cables or wires or wirelessly.

In the fourth picking unit 320, the fourth front doffer assembly 342 maybe electrically powered by a fourth front motor 368. The fourth reardoffer assembly 344 may be electrically powered by a fourth rear motor370. The front motor 368 and rear motor 370 may each be electricallycoupled or at least in electrical communication with the fourthcontroller/inverter 354. Electrical wires or cables may electricallycouple the fourth controller/inverter 354 to each of the fourth motors,or communication may be via wireless communication.

In each picking unit, the respective controller/inverter may beelectrically coupled or in electrical communication via electricalcommunication line 372 with the generator unit 306 and electronics 308.Moreover, each controller/inverter may be in communication with the maincontroller 310 via the CAN bus 312 or any other communication line. Thecontroller/inverter of each picking unit may receive from or sendcommands via a command line 374 to the main controller 310. Thesecommands may relate to inputs received from each motor. Inputs mayinclude torque, speed, temperature, etc.

Thus, in the illustrated embodiment of FIG. 3, each front dofferassembly is electrically powered by a front electric motor, and eachrear doffer assembly is electrically powered by a rear electric motor.Turning to FIG. 4, however, is a related embodiment in which theindependent doffer assemblies are electrically powered by a singleelectric motor. For sake of simplicity, reference numbers are similarbetween the embodiments of FIGS. 3 and 4 as it relates to the differentsystem components.

In FIG. 4, a control system 400 for a cotton harvester unit isillustrated. Similar to the control system 300 of FIG. 3, the controlsystem 400 in FIG. 4 may include a main controller 410. The cottonharvester unit may include a drive unit such as an engine 402 thatprovides mechanical power 446 to a gearbox or auxiliary drive unit 404.A generator unit 406 may convert the mechanical power to electricalpower, and electronics 408 for voltage command may be in electricalcommunication with the main controller 410.

The harvester unit may include a plurality of picking units. Similar tothe embodiment of FIG. 3, the plurality of picking units in FIG. 4 mayinclude a first picking 414, a second picking 416, a third picking unit418, and a fourth picking 420. Each picking unit may include its owncontroller/inverter that is disposed in electrical communication via anelectrical line 472 to the generator unit 406 and electronics 408.Moreover, the main controller 410 may communicate with eachcontroller/inverter via a CAN bus 412.

The first picking unit 414 may include a first controller/inverter 448,a first drum and spindle drive 422, a first front doffer assembly 424and a first rear doffer assembly 426. The second picking unit 416 mayinclude a second controller/inverter 450, a second drum and spindledrive 428, a second front doffer assembly 430, and a second rear dofferassembly 432. The first drum and spindle drive 422 may be mechanicallycoupled to the second drum and spindle drive 428, as shown in FIG. 4.Mechanical power 446, e.g., from the engine 402, may mechanically powerthe drum and spindle drives. Alternatively, other power sources(including electric or hydraulic) may drive the drum and spindle drives.

The third picking unit 418 may include a third controller/inverter 452,a third drum and spindle drive 434, a third front doffer assembly 436,and a third rear doffer assembly 438. The fourth picking unit 420 mayinclude a fourth controller/inverter 454, a fourth drum and spindledrive 440, a fourth front doffer assembly 442, and a fourth rear dofferassembly 444. The third drum and spindle drive 434 may be mechanicallycoupled to the fourth drum and spindle drive 440, as shown in FIG. 4.Mechanical power 446, e.g., from the engine 402, may mechanically powerthe drum and spindle drives. Alternatively, other power sources(including electric or hydraulic) may drive the drum and spindle drives.

The control system 400 of FIG. 4 differs from that in FIG. 3 in thatonly a single electrical motor is provided for each picking unit. Forexample, the first front doffer assembly 424 and the first rear dofferassembly 426 are electrically powered by a single electrical motor 456.It is still worth noting that the doffer assemblies are electricallypowered independently from the drum and spindle drive 422, but ratherthan each doffer assembly being powered by an independent motor, thefirst motor 456 electrically powers both the first front doffer assembly424 and the first rear doffer assembly 426. The same is true withrespect to the other picking units. For example, a second electricalmotor 458 electrically powers the second front doffer assembly 430 andthe second rear doffer assembly 432. A third electrical motor 460electrically powers the third front doffer assembly 436 and the thirdrear doffer assembly 438. Moreover, a fourth electrical motor 462electrically powers the fourth front doffer assembly 442 and the fourthrear doffer assembly 444.

Each controller/inverter may be electrically coupled or at least inelectrical communication with each respective motor. The motor may sendinputs to the controller/inverter related to a load (e.g., torque),speed, temperature or other input. The controller/inverter may send orreceive commands via a command line 474 to another controller/inverteror the main controller 410. Alternatively, communication may be via theCAN bus 412. In any event, the same functionality and benefits may beachieved with the single motor per row unit system as shown in FIG. 4.

In the illustrated embodiment of FIG. 4, it is further shown that thefront and rear doffer assemblies are mechanically coupled to oneanother. In other words, the electric motor may electrically powereither the front or rear doffer assembly, and the other doffer assemblyis mechanically coupled to the hydraulically driven doffer assembly. Themechanical coupling (e.g., shafts, gears, etc.) allows a single electricmotor to electrically power both doffer assemblies simultaneously.

Although not shown, another embodiment of an independentelectrically-powered doffer drive system may include a single motor forpowering all of the front and rear doffer assemblies of the cottonharvester unit. In other words, rather than each picking unit having itsown electric motor, in this embodiment there is only one motor forpowering all of the doffer assemblies. Taking FIG. 4 for example, inthis embodiment a single motor would replace the first motor 456, secondmotor 458, third motor 460, and fourth motor 462. The single motor wouldelectrically power the front and rear doffer assemblies of the first,second, third and fourth picking units. In this embodiment, there mayonly be a single controller/inverter for the single motor.

Referring to FIG. 5, a different embodiment of a cotton harvester unitwill now be described. Here, a control system 500 is provided in whichan independent doffer drive is powered hydraulically rather thanelectrically. In this embodiment, the cotton harvester unit may includea drive unit such as an engine 502 for providing mechanical power to acoupling gearbox or auxiliary drive unit 504. The power may betransferred for driving a hydraulic pump 506. An electrical controlvalve 508 may also be included and which is in communication with a maincontroller 510 or HIC. Communication may be via a CAN link 512 or othercommunication link. In any event, the pump 506 may provide hydraulicpower via hydraulic lines 572 to a plurality of picking units.

In FIG. 5, the plurality of picking units may include a first pickingunit 514, a second picking 516, a third picking unit 518, and a fourthpicking 520. Each picking unit includes a drum and spindle drive, afront doffer assembly and a rear doffer assembly. In the first pickingunit 514, for example, a first drum and spindle drive 522, a first frontdoffer assembly 524 and a first rear doffer assembly 524 are provided.The second picking 516 may include a second drum and spindle drive 528,a second front doffer assembly 530 and a second rear doffer assembly532. The third picking unit 518 may include a drum and spindle drive534, a front doffer assembly 536 and a rear doffer assembly 538. Thefourth picking unit 520 may include a drum and spindle drive 540, afront doffer assembly 542, and a rear doffer assembly 544.

In this embodiment, mechanical power 546 may be provided by the engine502 to mechanically power the drum and spindle drives. In FIG. 5, forexample, the first and second drum and spindle drives 522, 528 may bemechanically coupled to one another, and the third and fourth drum andspindle drives 534, 540 may be mechanically coupled to one another. In adifferent embodiment, all of drum and spindle drives may be mechanicallycoupled to one another.

Each picking unit may include its own hydraulic valves which receivehydraulic power from the pump 506. For instance, a first hydraulic valveor valves 548 may be provided for the first picking unit 514. The secondpicking unit 516 may include a second hydraulic valve or valves 550, thethird picking unit 518 may include a third hydraulic valve or valves552, and the fourth picking unit 520 may include a fourth hydraulicvalve or valves 554.

Each of the hydraulic valve or valves may be hydraulically coupled to afront hydraulic motor and a rear hydraulic motor for each picking unit.In FIG. 5, the hydraulic motors are illustrated as being hydraulicallyplumbed in parallel with respect to one another. In another embodiment,however, the front and rear motors may be hydraulically plumbed inseries.

As shown, the first hydraulic valve or valves 548 may provide hydraulicfluid to a first front hydraulic motor 556 and a first rear hydraulicmotor 558. The front hydraulic motor 556 may hydraulically power thefront doffer assembly 524, and the rear hydraulic motor 558 mayhydraulically power the rear doffer assembly 526. The second hydraulicvalve or valves 550 may provide hydraulic fluid to a second fronthydraulic motor 560 and a second rear hydraulic motor 562. The fronthydraulic motor 560 may hydraulically power the front doffer assembly530, and the rear hydraulic motor 562 may hydraulically power the reardoffer assembly 532. Similarly, the third hydraulic valve or valves 552may provide hydraulic fluid to a third front hydraulic motor 564 and athird rear hydraulic motor 566. The front hydraulic motor 564 mayhydraulically power the front doffer assembly 536, and the rearhydraulic motor 566 may hydraulically power the rear doffer assembly538. Lastly, the fourth hydraulic valve or valves 554 may providehydraulic fluid to a fourth front hydraulic motor 568 and a fourth rearhydraulic motor 570. The front hydraulic motor 568 may hydraulicallypower the front doffer assembly 542, and the rear hydraulic motor 570may hydraulically power the rear doffer assembly 544.

In each picking unit, the hydraulic valve or valves may be hydraulicallycoupled to the front and rear motors via a supply line and a returnline. Moreover, a pressure or speed sensor (not shown) may be part ofthe control system for measuring a fluid pressure, flow rate, orrotational speed of each doffer drive. The sensor(s) may be incommunication with the main controller 510 for controlling operation ofthe valves and hydraulic motors. Commands and feedback may becommunicated to or from the valves via the CAN bus 512. Thiscommunication may relate to pressure or flow, for example. In any event,a plugged condition or doffer wear may be detected by the maincontroller 510 due to communication with the valves and sensors.

In FIG. 6, a related embodiment for independent hydraulic control of thedoffer drives is shown. Here, many of the same components form a controlsystem 600 similar to that in FIG. 5. In this system, however, a singlemotor drives the front and rear doffer assemblies in each picking unit.Thus, this embodiment is similar to that of FIG. 4 in which each pickingunit includes a single motor.

In the illustrated embodiment of FIG. 6, the cotton harvester unit mayinclude a drive unit such as an engine 602 for providing mechanicalpower to a coupling gearbox or auxiliary drive unit 604. The power maybe transferred for driving a hydraulic pump 606. An electrical controlvalve 608 may also be included and which is in communication with a maincontroller 610. Communication may be via a CAN link 612 or othercommunication link. In any event, the hydraulic pump 606 may providehydraulic fluid via hydraulic lines 672 to a plurality of picking units.

In FIG. 6, the plurality of picking units may include a first pickingunit 614, a second picking 616, a third picking unit 618, and a fourthpicking 620. Each picking unit includes a drum and spindle drive, afront doffer assembly and a rear doffer assembly. In the first pickingunit 614, for example, a first drum and spindle drive 622, a first frontdoffer assembly 624 and a first rear doffer assembly 624 are provided.The second picking 616 may include a second drum and spindle drive 628,a second front doffer assembly 630 and a second rear doffer assembly632. The third picking unit 618 may include a drum and spindle drive634, a front doffer assembly 636 and a rear doffer assembly 638. Thefourth picking unit 620 may include a drum and spindle drive 640, afront doffer assembly 642, and a rear doffer assembly 644.

In this embodiment, mechanical power 646 may be provided by the engine602 to mechanically power the drum and spindle drives. In FIG. 6, forexample, the first and second drum and spindle drives 622, 628 may bemechanically coupled to one another, and the third and fourth drum andspindle drives 634, 640 may be mechanically coupled to one another. In adifferent embodiment, all of drum and spindle drives may be mechanicallycoupled to one another.

Each picking unit may include its own hydraulic valves which receivehydraulic power from the pump 606. For instance, a first hydraulic valveor valves 648 may be provided for the first picking unit 614. The secondpicking unit 616 may include a second hydraulic valve or valves 650, thethird picking unit 618 may include a third hydraulic valve or valves652, and the fourth picking unit 620 may include a fourth hydraulicvalve or valves 654.

Each of the hydraulic valve or valves may be hydraulically coupled to afront hydraulic motor and a rear hydraulic motor for each picking unit.In FIG. 6, the hydraulic motors are illustrated as being hydraulicallyplumbed in parallel with respect to one another. In another embodiment,however, the front and rear motors may be hydraulically plumbed inseries.

As shown, the first hydraulic valve or valves 648 may provide hydraulicfluid to a first hydraulic motor 656. The first hydraulic motor 656 mayhydraulically power the front doffer assembly 624 and the rear dofferassembly 626. The second hydraulic valve or valves 650 may providehydraulic fluid to a second hydraulic motor 658. The second hydraulicmotor 658 may hydraulically power the front doffer assembly 630 and therear doffer assembly 632. Similarly, the third hydraulic valve or valves652 may provide hydraulic fluid to a third hydraulic motor 660. Thethird hydraulic motor 660 may hydraulically power the front dofferassembly 636 and the rear doffer assembly 638. Lastly, the fourthhydraulic valve or valves 654 may provide hydraulic fluid to a fourthhydraulic motor 662, which in turns may hydraulically power the frontdoffer assembly 642 and the rear doffer assembly 644.

In each picking unit, the hydraulic valve or valves may be hydraulicallycoupled to the respective motor via a supply line and a return line.Moreover, a pressure or speed sensor (not shown) may be part of thecontrol system for measuring a fluid pressure, flow rate, or rotationalspeed of each doffer drive. The sensor(s) may be in communication withthe main controller 610 for controlling operation of the valves andhydraulic motors. Commands and feedback may be communicated to or fromthe valves via the CAN bus 612. This communication may relate topressure or flow, for example. In any event, a plugged condition ordoffer wear may be detected by the main controller 610 due tocommunication with the valves and sensors.

In the illustrated embodiment of FIG. 6, it is further shown that thefront and rear doffer assemblies are mechanically coupled to oneanother. In other words, the hydraulic motor may hydraulically powereither the front or rear doffer assembly, and the other doffer assemblyis mechanically coupled to the hydraulically driven doffer assembly. Themechanical coupling (e.g., shafts, gears, etc.) allows a singlehydraulic motor to hydraulically power both doffer assembliessimultaneously.

In FIG. 6, each picking unit includes its own hydraulic motor. Inanother but related embodiment, there may be a single hydraulic motorfor hydraulically powering the front and rear doffer assemblies of allof the picking units. In this embodiment, a single hydraulic valve orvalves may be in fluid communication with the pump and the singlehydraulic motor. Supply and return hydraulic lines may be coupledbetween the single valve or valves and the single motor.

Referring to FIG. 7, a different embodiment of a cotton harvester unitand independent doffer drive system is shown. In this system, a controlsystem 700 is provided for independent mechanical doffer drivecapability. The control system 700 may include a main controller 710 andthe harvester unit may include a drive unit such as an engine 702 forproviding mechanical power. The engine 702 may provide mechanical powerto a gearbox or auxiliary drive unit 704 for driving a hydraulic pump706. An electronic control valve 708 may be in electrical communicationwith the main controller 710 via a wireless link, a wired link, or a CANbus 712. The hydraulic pump 706 may provide hydraulic power via a fluidlink 772 to a first hydraulic valve or valves 748 and a second hydraulicvalve or valves 750. The valves will be described in further detailbelow.

Similar to the previously described embodiments, the cotton harvesterunit may include a plurality of picking units. Any number of pickingunits may be provided, and this disclosure is not limited to anyparticular number. In FIG. 7, a first picking unit 714, a second pickingunit 716, a third picking unit 718, and a fourth picking unit 720 areprovided. Each picking unit may include its own drum and spindle drive,a front doffer assembly and a rear doffer assembly. In otherembodiments, there may only be a single drum drive, a single spindledrive, and a single doffer assembly.

The first picking unit 714 may include a first drum and spindle driveunit 722, a first front doffer assembly 724, and a first rear dofferassembly 726. The second picking unit 716 may include a second drum andspindle drive 728, a second front doffer assembly 730, and a second reardoffer assembly 732. The third picking unit 718 may include a third drumand spindle drive 734, a third front doffer assembly 736, and a thirdrear doffer assembly 738. The fourth picking unit 720 may include afourth drum and spindle drive 740, a fourth front doffer assembly 742,and a fourth rear doffer assembly 744.

The drum and spindle drives may be mechanically powered. For example,mechanical power 746 may be provided by the engine 702 to mechanicallypower each drum and spindle drive. The first drum and spindle drive 722may be mechanically coupled to the second drum and spindle drive 728 viamechanical link 752. The mechanical link 752 may include gears, shafts,gearsets, etc. for transferring mechanical power. Similarly, the thirddrum and spindle drive 734 may be mechanically coupled to the fourthdrum and spindle drive 740, as shown. Here, mechanical power 746 fromthe engine 702 may be provided to the third drum and spindle drive 734,and mechanical power may be transferred via mechanical link 752 to thefourth drum and spindle drive 740. Thus, there is a mechanical couplingof drum and spindle drives between row units.

In FIG. 7, the first valve or valves 748 may provide hydraulic fluid todrive a first hydraulic motor 756. Likewise, the second valve or valves750 may provide hydraulic fluid to drive a second hydraulic motor 758. Asupply and return line may be provided between the respective valve orvalves and hydraulic motor.

The first valve or valves 748 may provide hydraulic fluid to drive thefirst hydraulic motor 756, which in turn drives the first rear dofferassembly 726. The first rear doffer assembly 726 may be mechanicallycoupled via mechanical link 752 with the first front doffer assembly 724such that the first hydraulic motor 756 drives both the front and reardoffer assemblies in the same row unit. Moreover, the second frontdoffer assembly 730 and second rear doffer assembly 732 may bemechanically coupled via mechanical link 752 to one another. The secondrear doffer assembly 732 may further be mechanically coupled viamechanical link 752 to the first rear doffer assembly 726 such that thefirst hydraulic motor 756 drives the second front and rear dofferassemblies via mechanical couplings between row units.

The same may be true of the third and fourth picking units. The secondvalve or valves 750 may provide hydraulic fluid to drive the secondhydraulic motor 758, which in turn drives the fourth rear dofferassembly 744. The fourth rear doffer assembly 744 may be mechanicallycoupled via mechanical link 752 with the fourth front doffer assembly742 such that the second hydraulic motor 758 drives both the front andrear doffer assemblies in the same row unit. Moreover, the third frontdoffer assembly 736 and third rear doffer assembly 738 may bemechanically coupled via mechanical link 752 to one another. The thirdrear doffer assembly 738 may further be mechanically coupled viamechanical link 752 to the fourth rear doffer assembly 744 such that thesecond hydraulic motor 758 drives the third front and rear dofferassemblies via mechanical couplings 752 between row units.

Pressure and flow commands may be communicated between the maincontroller 710 and the first and second valves 748, 750. Feedback fromthe doffers may be provided via sensors (e.g., speed sensors, pressuresensors, flow sensors, etc.) to the main controller 710 for detectingwear or a plugged condition. The main controller 710 can thereforedetect wear or the plugged condition by comparing torque, speed,pressure, flow, etc. to one or more threshold conditions. For example,if the main controller 710 detects a sudden spike in motor torque, thecontroller 710 may compare the torque to a torque threshold and detect aplugged condition. Once the plugged condition is detected, thecontroller 710 can send commands to the first and second valves tocontrol the hydraulic motors and provide independent control of thedoffer assemblies to assist with removing the plugged cotton. Forexample, the drum and spindle drives may be mechanically driven in areverse direction, while the controller 710 maintains the dofferassemblies rotating in a normal, forward direction. In doing so, cottonmay be unwound from the plurality of spindles to clear the pluggedcondition. This type of control may be implemented in any of theaforementioned embodiments described in this disclosure.

Further, a gradual increase in motor torque may be detected by the maincontroller and compared to a torque threshold. If the torque exceeds thethreshold, the controller may interpret this gradual increase in torqueas excessive doffer wear. A signal or alert may be communicated to amachine operator via a dashboard or other communication device so thatappropriate maintenance and corrective action may be taken. This type ofprognostic care may be implemented in any of the embodiments describedherein. As such, the cotton harvester may achieve efficient doffing withincreased productivity by being able to monitor doffer wear andautomatically clear plugs from individual row units.

While this disclosure has been described with respect to at least oneembodiment, the present disclosure can be further modified within thespirit and scope of this disclosure. This application is thereforeintended to cover any variations, uses, or adaptations of the disclosureusing its general principles. Further, this application is intended tocover such departures from the present disclosure as come within knownor customary practice in the art to which this disclosure pertains andwhich fall within the limits of the appended claims.

1. A doffer assembly for a cotton harvester having at least one drum anda spindle, comprising: an outer housing; a plurality of doffers adaptedto remove cotton from the spindle of the harvester; a drive unit coupledto the outer housing for rotatably driving the plurality of doffersindependently of the at least one drum and spindle; a drive shaftrotatably driven by the drive unit; and an interface adapter coupledbetween the drive shaft and the plurality of doffers.
 2. The dofferassembly of claim 1, further comprising: a drive coupler coupled to thedrive shaft; and a driven coupler coupled to the drive coupler and theinterface adapter.
 3. The doffer assembly of claim 1, wherein the driveunit comprises an electric or hydraulic motor.
 4. The doffer assembly ofclaim 1, wherein the drive unit is axially aligned with the plurality ofdoffers.
 5. The doffer assembly of claim 1, further comprising a dofferadjustment device for axially adjusting the plurality of doffersrelative to the doffer housing, the doffer adjustment device including adoffer adjustment shaft and a doffer adjustment ring gear.
 6. A pickerunit assembly of a cotton harvester, comprising: a drum and a pluralityof spindles rotatably coupled to the drum; a drum and spindle drive unitfor rotatably driving the drum and the plurality of spindles; a dofferassembly including a plurality of doffers configured to remove cottonfrom the plurality of spindles; and a doffer drive unit for rotatablydriving the doffer assembly, wherein the doffer drive unit rotatablydrives the doffer assembly independently of the plurality of spindles.7. The picker unit assembly of claim 6, wherein the doffer drive unitcomprises an electric motor.
 8. The picker unit assembly of claim 7,further comprising an inverter for providing electrical power to themotor for driving the doffer assembly, the inverter further adapted todetect a condition related to doffer wear or a plug based on feedbackreceived from the motor.
 9. The picker unit assembly of claim 6, furthercomprising a second doffer assembly including a plurality of doffersconfigured to remove cotton from a second plurality of spindles, whereinthe second doffer assembly is rotatably driven independently of thefirst and second plurality of spindles.
 10. The picker unit assembly ofclaim 9, wherein the doffer drive unit rotatably drives both the firstand the second doffer drive assemblies.
 11. The picker unit assembly ofclaim 9, further comprising: a second doffer drive unit for rotatablydriving the second doffer assembly; and an inverter for electricallypowering the first and second doffer drive units.
 12. The picker unitassembly of claim 6, wherein the doffer drive unit comprises a hydraulicmotor for hydraulically powering the plurality of doffers.
 13. Thepicker unit assembly of claim 12, further comprising: a second dofferassembly including a plurality of doffers configured to remove cottonfrom a second plurality of spindles, wherein the second doffer assemblyis rotatably driven independently of the first and second plurality ofspindles; and a second doffer drive unit for hydraulically powering thesecond doffer assembly.
 14. A cotton harvester, comprising: a drive unitfor producing mechanical power; a controller for controlling the cottonharvester; a plurality of picker units configured to harvest cotton,wherein each of the plurality of picker units comprises: a drum; aplurality of spindles rotatably coupled to the drum; a drum and spindledrive for rotatably driving the drum and the plurality of spindles; adoffer assembly including a plurality of doffers configured to removecotton from the plurality of spindles; and a doffer drive unit forrotatably driving the doffer assembly, wherein the doffer drive unitrotatably drives the doffer assembly independently of the drum andspindle drive.
 15. The cotton harvester of claim 14, wherein the dofferdrive unit comprises an electric motor or hydraulic motor.
 16. Thecotton harvester of claim 14, wherein the plurality of picking unitscomprises a first picking unit and a second picking unit, the firstpicking unit and the second picking unit each including a doffer driveunit and a doffer assembly, the doffer drive unit comprising a frontdoffer drive unit and a rear doffer drive unit, and the doffer assemblycomprising a front doffer assembly and a rear doffer assembly; furtherwherein, the front doffer drive unit of the first and second pickingunits operably drives the respective front doffer assembly, and the reardoffer drive unit of the first and second picking units operably drivesthe respective rear doffer assembly.
 17. The cotton harvester of claim16, further comprising: a first inverter for electrically controllingthe front doffer drive unit and rear doffer drive unit of the firstpicking unit; and a second inverter for electrically controlling thefront doffer drive unit and rear doffer drive unit of the second pickingunit; wherein, the first inverter and second inverter are in electricalcommunication with the controller.
 18. The cotton harvester of claim 16,further comprising: a hydraulic pump operably driven by the drive unit;a first hydraulic valve fluidly coupled to the hydraulic pump, the firsthydraulic valve hydraulically controlling the front doffer drive unitand rear doffer drive unit of the first picking unit; and a secondhydraulic valve fluidly coupled to the hydraulic pump, the secondhydraulic valve hydraulically controlling the front doffer drive unitand rear doffer drive unit of the second picking unit.
 19. The cottonharvester of claim 14, wherein: the plurality of picking units comprisesa first picking unit and a second picking unit; the doffer assembly ofthe first picking unit comprises a first front doffer assembly and afirst rear doffer assembly; the doffer assembly of the second pickingunit comprises a second front doffer assembly and a second rear dofferassembly; the doffer drive unit of the first picking unit operablydrives the first front doffer assembly and the first rear dofferassembly; and the doffer drive unit of the second picking unit operablydrives the second front doffer assembly and the second rear dofferassembly.
 20. The cotton harvester of claim 14, further comprising: ahydraulic pump operably driven by the drive unit; a first picking unitof the plurality of picking units, the first picking unit including afirst front doffer assembly and a first rear doffer assembly, where thedoffer drive unit operably drives the first rear doffer assembly; asecond picking unit of the plurality of picking units, the secondpicking unit including a second front doffer assembly and a second reardoffer assembly; and a hydraulic valve fluidly coupled to the hydraulicpump, the hydraulic valve hydraulically controlling the first dofferdrive unit; wherein, the first front doffer assembly and the first reardoffer assembly are mechanically coupled to one another, and the secondfront doffer assembly and the second rear doffer assembly aremechanically coupled to one another; wherein, the first rear dofferassembly and the second rear doffer assembly are mechanically coupled toone another; further wherein, the second front doffer assembly and thesecond rear doffer assembly are rotatably driven by the doffer driveunit via the mechanical coupling between the first rear doffer assemblyand the second rear doffer assembly.